Sr. Manufacturing Controls Dev Engineer, Automation & Robotics

Tesla’s Materials Manufacturing Engineering team is at the forefront of developing first-of-a-kind processes which allow us to produce amazing vehicles at best-in-class quality and rate, in a safe and ergonomic environment. Materials Manufacturing Engineering is seeking a Controls Engineer to lead the design, development, deployment, commissioning, troubleshooting, and optimization of fully automated robotic and conveyance systems within our paint and powder coating manufacturing lines. You will lead the design and develop technically complex controls, electrical, and automation systems within new manufacturing lines, while being responsible for implementing and managing continuous process optimization—incorporating both advanced and conventional technologies to improve quality, boost productivity, and reduce overall waste. The candidate will partner with cross-functional teams, automation vendors, and robotics integrators to deliver scalable, reliable, and high-performance automation solutions that meet Tesla’s aggressive quality, throughput, and safety standards.

Responsibilities

Design and commission automated conveyor systems (e.g., chain, roller, belt, overhead monorail, AGV, AMR) with precise positioning, speed control, and fault tolerance, integrated with robotic and process equipment Lead the design and implementation of fully automated robotic painting and powder coating systems, including robot path planning, cycle time optimization, and integration with high-speed conveyance Develop and debug advanced robotic programs (Fanuc, Kuka, ABB, Durr) for complex coating applications, including interlocks with specialty dispense and application equipment, process equipment and conveyance Lead the assessment, selection, and integration of machine vision systems (Cognex, Keyence, Fanuc) for automated part inspection, orientation, and coating application verification across robotic application cells and conveyance lines Participate in initial equipment conceptual development and carefully balance product specifications, process requirements, layout complexity, cost, and lead-time limits Lay out new industrial electrical control panels which are NFPA79/NEC/UL508A compliant, and create electrical, pneumatic and fluid schematics including electrical cabinet builds, field wiring, pneumatic and fluid plumbing Architect, develop and debug PLC code with an emphasis on generating code that is organized, structured, documented, maintainable and reusable - PLC code will interact with subsystems such as conveyors, robots, Manufacturing Execution System (MES), LabView, machine vision, and 3rd party equipment Generate, optimize & improve aesthetically simple HMI screens, SCADA Systems & MES Interfaces for complex machinery Develop and implement quality control methods including poke yokes, data tracking systems, part recognition and problem reporting Ensure that all equipment, processes and methodologies comply with applicable standards, company policy and all Health and Safety Laws, Acts, Regulations and Codes

Requirements

Degree in Electrical Engineering, Controls Engineering, Mechatronic Engineering, Automation Engineering, or equivalent experience 5+ years of professional controls engineering experience including advanced PLC programming & Motor controller programming (Rockwell, Siemens and equivalent PLCs with safety controllers) Demonstrate conceptual proficiency in the development of electrical and controls architectures for new equipment and manufacturing lines Demonstrated proficiency in PLC, HMI (Ignition, Siemens), and debugging mechatronic systems Understanding of databases (MSSQL, MySQL), Object-Oriented Programming languages (Java, Python, etc.), and CAD (AutoCAD, CATIA, SolidWorks, EPLAN) Advanced robotics programming skills (Fanuc, Kuka, Durr, ABB, etc.) In depth knowledge of Electrical Standards (NFPA79, NEC, UL508A) and safety standards (ANSI/RIA, OSHA) Proficiency selecting appropriate circuit protectors, wire, cable, sensors, safety hardware, PLC hardware, remote I/O, VFD, robots and servo systems Experience with vision systems (Cognex, Keyence, Fanuc) Experience working with automotive manufacturing processes & equipment preferred